STRUCTURAL PRECAST - FP MCCANN
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STRUCTURAL
PRECAST
v1.3
FPMCCANN.CO.UK
UD D IN G STO N
K I L R EA A LN W IC K
M A G H E R A FELT W E STO N UN D E R W O O D
E LLISTO W N
L I S N A S K EA A R M AG H
B YLE Y
G R A N TH A M
LITTLE PO RT
LY D N EY
CA D E B Y
FP McCann is the UK’s market leader in the manufacture, supply and delivery of precast concrete solutions. Our comprehensive
precast concrete business extends to include:
AGRICULTURE | ARCHITECTURAL PRECAST | BOX CULVERTS | BUILDING PRODUCTS
DOCK LEVELLER PITS | DRAINAGE | FENCING | FILTER BED SYSTEMS | FLOORING
POWER & INFRASTR UCTURE | RAIL | SPECIALIST PRECAST | STRUCTURAL PRECAST
TANKS & CHAMBERS | TUNNELS & SHAFTS | WALLING
Modern manufacturing plants at Alnwick (Northumberland), Armagh (Northern Ireland), Byley (Cheshire), Cadeby (Warwickshire), Ellistown
(Leicestershire), Grantham (Lincolnshire), Lisnaskea (Northern Ireland), Littleport (Cambridgeshire), Lydney (Gloucestershire), Magherafelt
(Northern Ireland), Uddingston (Lanarkshire) and Weston Underwood (Derbyshire) incorporate the latest computerised batching, distribution,
casting, curing and handling systems and are operated by skilled and experienced workforces to ensure consistency of quality. Their
geographical spread gives us an unrivalled ability to serve the construction industry throughout the UK and Ireland.
By applying the DFMA principles, FP McCann’s design engineers are able to evaluate individual precast concrete products part by part, in
addition to documenting the assembly process step by step. This allows them to generate the cost, part count and assembly time to provide
a benchmark to measure its success and identify the parts and process improvement opportunities. In turn, this has allowed FP McCann to
design and manufacture more cost-effective and efficient high-quality precast concrete products with less wastage and greater on-site recycling.
As a result, increased productivity, combined with a reduction in production time and costs, allows FP McCann to be more competitive within the
marketplace.
Please note: all information is correct at time of going to print.
CONTENTS
At FP McCann, we believe in working with you as
a partner from the start, which means offering our
expertise in designing and manufacturing rooms to
suit all your individual project needs. Far from being
an off-the-shelf solution, our precast structural
solutions are made-to-measure, whilst maintaining
our design philosophies and standard details.
Crosswall Construction 4
The Concept and Design 5
Production 6
The System 7
Insulated Precast Sandwich Panels 8
Lift Shafts 9
Hotels 10
Education 12
Student Accommodation 14
Secure Accommodation 18
Health 20
Private & Social Housing 22
Car Parks & Frames / Groundbeams 24
Sustainable Performance 25
Project List 26
Photo Credit: Paul Miller / Alumno Developments
CROSSWALL
CONSTRUCTION
Precast concrete crosswall construction is a fast, It can be tailored to meet the needs of the client, architect,
engineer and builder.
convenient way to produce multi-unit structures
such as hotels, education, student, secure and All units are manufactured off-site at our Byley and Grantham
depots and are delivered to site ready for final preparation and
health accommodation, private and social housing in decoration. All sections are designed for ease of construction,
a fraction of the time of traditionally built structures. fitting together to conform fully with building and structural
regulations. Also, since the windows are fixed, internal trades can
It has all the advantages of a factory engineered system, including commence work far earlier than on a traditional-build site. All this
ISO 9001 and ISO 14001 quality assured production and provides to ensure peace of mind for you when you partner with us.
a highly flexible layout.
4 | fpmccann.co.uk/structural
THE CONCEPT The concept of crosswall is uncomplicated, unlike
the conventional building process where one trade
has to follow on after the other; this system allows
the main structure to be completed very quickly.
E STI MATE DESIGN M A NUFA C T UR E INS TA LLAT ION
Once the foundations are laid, the speed of construction takes
over. FP McCann supplies the pre-formed units, including all walls
and floors and a flat slab concrete roof to provide an enclosed
weathertight working area.
The main load-bearing structure is completed within weeks and
protected from the weather. If required, fully fitted-out bathroom
pods can be incorporated during this stage.
All follow-on trades can be scheduled to commence
simultaneously. Roof, brickwork, window, services and floor
screed subcontractors all work together to drastically reduce the
time required to complete the final construction.
DESIGN
FP McCann has established a reputation for
providing a wide range of concrete solutions for
technically demanding projects that require a
precision seldom associated with precast concrete.
Client designs are progressed using the latest
CAD and drafting systems, including 3D modelling,
ensuring BIM compatibility and providing optimum
design and build solutions.
The crosswall system is designed in accordance with Building
Regulation requirements and current British Standards, particularly
BS EN 1992 (Eurocode 2).
Unless specified otherwise loadings are generally to the latest
revision of BS EN 1991 (Eurocode 1).
Walls are generally designed as plain walls to Eurocode 2 and are
reinforced locally over windows and at openings etc. Floors can
be prestressed hollowcore planks, solid reinforced or prestressed
concrete slabs.
fpmccann.co.uk/structural | 5
PRODUCTION Precast crosswall components are produced at
FP McCann’s modern factories, which are Quality
and Environment Accredited to ISO 9001 QMS and
ISO 14001 EMS. All aspects of the production cycle
are carried out in strict accordance with British
Standards and the clients’ own requirements.
FP McCann’s experience and knowledge of off-site construction
ensures that all products are designed and manufactured for ease
of assembly.
The manufacturing process is carried out by a highly skilled and
experienced workforce. Concrete of the exact specifications
is batched automatically by the automated mixing plants, then
distributed by bullet skips to a precise location within the factory.
Q U A LI TY ASSURANCE
FP McCann operates a quality management system which
complies with the requirements of ISO 9001 for the design and
manufacture of precast concrete products.
FP McCann is committed to working closely with its customers,
providing products and services to meet their construction and
engineering needs.
Each factory has its own independent Quality Inspector to ensure
compliance with ISO standards.
6 | fpmccann.co.uk/structural
THE SYSTEM The precast crosswall structural engineering system
comprises a series of concrete panels forming
internal, structural load-bearing and partition walls,
external walls and floor slabs. External walls can
consist of just the inner leaf concrete finish or
include the insulated precast sandwich panels.
Overall stability is achieved by the diaphragm action of the floor Robustness of the structure is achieved through the provision of
slabs, transforming horizontal loads between precast wall panels horizontal internal and peripheral ties, together with vertical ties.
acting as shear walls.
The provision of these ties ensures that disproportionate collapse
In common with all other wall units used in the system, the shear of the structure is prevented in the event of an explosion or other
walls are structurally connected together using in-situ concrete localized accidental damage.
stitched joints, which are designed, detailed and constructed to
ensure full transfer of all forces acting on the structure, and to The stairways and landings are formed in precast concrete and are
ensure transfer of loads to the foundations. supported by the wall panel system by hidden connections and
grouted joints.
The system allows for very simple, structurally independent
foundations and roof constructions to be used.
In addition to the benefits of quality,
programme saving and robustness, the
thermal storage capacity of concrete
can be used to reduce the heating
costs of the building and provide an
even internal climate.
8
9
5
6
7
1
2
4
3
1. External cladding 6. Horizontal tie reinforcement
2. Non-load bearing partition 7. External load bearing
wall partition wall panel
3. Simple independent 8. Solid floors without screed
foundation or hollowcore floor with
4. Stairs and landings minimum 50mm screed
5. Vertical tie reinforcement 9. Bathroom pods
fpmccann.co.uk/structural | 7
INSULATED FP McCann’s insulated precast sandwich panels
provide a ready-made external envelope with a
PRECAST variety of finishes. This eliminates many of the
pitfalls associated with traditional building methods
SANDWICH utilising wet trades.
PANELS
The panels are constructed off-site and comprise an outer leaf of S A NDWIC H PA NE L C R O S S - S E C T IO N
precast concrete, an insulating layer and a structural inner leaf of
plain grey concrete with a power floated internal finish.
The external skin is connected to and supported by the internal
skin using proprietary plastic ties. The ties have a low thermal
Brickwork
conductivity which eliminates potential cold bridging.
We can modify the thickness of the insulation in order to Concrete
accommodate the required U-value. Shape, thickness and size of
the concrete can also be made to meet the requirements of the Insulation
project.
Concrete
Insulated sandwich panels can be used to drastically reduce
erection periods and on-site safety hazards for any crosswall
project. The ability to fit various facades, windows and insulation
during manufacture, reduces the need for numerous follow-on
trades and eliminates the need for scaffolding. FINIS H E S AVA ILA B LE INC LUDE :
• B R IC K FA C E D
FP McCann provides a free sampling service to • NAT UR A L S T O NE FA C E D
ensure we get the exact colour and texture required, • M O ULD FO R M E R S
including mortar pointing colours and finishes. • A C ID E T C H E D
• E X P O S E D A G G R E G AT E
8 | fpmccann.co.uk/structural
PRECAST
CONCRETE
LIFT SHAFTS
FP McCann manufactures precast modular lift
shafts which can be tailored to suit any project.
Since construction is completed off-site, the lift
shaft can be erected very quickly, which greatly
assists the build programme schedule.
B EN E FI TS
• Quick and easy to install
• Flexible, bespoke modular design
• Offsite construction minimises disruption on-site
• Minimal on-site labour and costs
• Minimal on-site health and safety risks
• Cast-in fittings provided for lift installation
• Factory-fitted and tested lifting beam/ sockets, if required
• Minimum one hour fire resistance
• Temporary works or propping is minimised or eliminated
• Can replace block work or act as shear walls
Working closely with your lift supplier, we can ensure that all
components are accurately positioned, including channels and
recesses.
FP McCann’s lift shafts can be built from 1200mm each way up to
2750mm, in increments of 50mm. Wall thickness starts at 150mm,
but this can be increased to 200mm or 250mm.
Our standard lift design supports all loading from the lift equipment
during installation, operation and maintenance. The lift shaft can
also be designed to support vertical loads from other structural
elements such as beams and slabs.
The precast pit section of the lift shaft is covered with a water
resisting concrete admixture to cast the lift pit sections. T UNNO C K S B IS C UIT FA C T O RY
Lift shafts that are at least four storeys high may need to be FP McCann has supplied three key precast concrete structural
restrained at intervals moving up the building, assumed to be elements on a brand new extension to the famous Thomas
achieved by tying back to the main structure. If shafts are to Tunnock chocolate confectionery factory based in Uddingston,
be erected ahead of the main structure, it may be necessary Scotland. When open, it will enable the company to increase
to provide temporary support. Please contact the technical production of its renowned caramel wafer biscuit` from 6.1 million
department for more information. bars a week to 7.2 million.
fpmccann.co.uk/structural | 9
HOTELS
FP McCann has long-standing experience within the hotel sector, providing
solutions to budget and luxury hotel chains including Ramada, Premier Inn,
Holiday Inn, Hilton, Crowne Plaza and Malmaison Hotels.
M OT E L ON E , MANCH ESTER panels for each bedroom, which were fitted and glazed at the
factory before delivery to site.
Motel One is a 330-bed hotel situated in the busy Piccadilly area of
Manchester. The hotel is fourteen and seven storeys respectively FP McCann played a key role in delivering this contemporary hotel.
and wraps around the Monroes Public House. Our meticulous planning enabled us to complete the project within
26 weeks, reducing normal build time by 50% whilst ensuring that
Using our factory engineered precast concrete system, which
our customer’s key performance requirements were met. These
included acid-etched composite panels in a Portland Hue colour,
included speed, quality, safety, programme and budget.
the façade comprised of large floor to ceiling glazed window
10 | fpmccann.co.uk/structuralR A MADA HOTEL , CR EW E P R E M IE R INN H OT E L, M A NC H E S T E R
FP McCann completed the design, manufacture and installation of the This hotel was constructed within a tightly constrained city centre site,
precast units for the Ramada Hotel, Crewe, using its precast crosswall which is at the junction of three busy routes in the Piccadilly area of
system to form four floors consisting of 112 bedrooms within a 10 Manchester, making delivery access difficult and leaving little room for
week period. on-site storage.
To ensure that installation could be completed in as little time as FP McCann’s off-site method of construction was therefore considered
possible without compromising quality, around 600 pieces were the ideal solution. Precast concrete components manufactured
manufactured at FP McCann’s Byley factory. off-site would ensure that the constricted site conditions would not
be an issue and the just-in-time delivery system would eliminate any
The crosswall construction system included recessed floors ready for problems regarding on-site storage.
receiving modular bathroom pods installed by FP McCann. Providing
this all-inclusive system meant that only minimal finishing work was The hotel was constructed using FP McCann’s specialised sandwich
needed with minimum screed to bring floors up to level. panels for the external walls and high quality precast concrete for all
internal walls and floors. The sandwich panels comprise 60mm of
Wall finishes were also minimised due to FP McCann’s battery mould insulation fitted with Thermomass ties between the inner and outer
manufacturing process with steel face framework on all internal sides. concrete leafs and were delivered already clad with ‘Aston Smooth’
This produced a high quality finish ready for a direct paint finish. brick and windows already installed at manufacture. This saved time
and money by increasing the speed of construction by up to one floor
per week and reduced the need for various follow-on trades.
The use of precast panels with brick cladding up to 11 storeys is
thought to be a UK first and a milestone project for FP McCann.
H ILTON HOTE L , T5 H EATH R O W
The luxury seven-storey Hilton Hotel, adjacent to Heathrow Airport’s
Terminal 5, required a construction solution that would maximise off-
site production processes, thus minimising the on-site programme.
This resulted in a reduction in the number of site personnel and M A LM A IS O N H OT E L, LIV E R P O O L
delivery vehicle movements that would have otherwise occurred. This was a complex project with double-storey, vertical external walls
to facilitate full height windows. The balconies were stepped from
FP McCann designed, manufactured and erected the precast concrete
the main finished floor levels, creating some interesting interfaces
crosswall frame, which consisted of 236 external and 432 internal
between elements. The requirement for double height walls presented
panels, each 150mm thick. In addition, approximately 761 floor and
an engineering challenge, due to the size and weight of the individual
roof units, as well as stairs and landings, were installed. FP McCann’s
panels. Due to its facade layout, stability of the panels and provision for
crosswall system is especially suitable for hotel construction, as each
disproportionate collapse required a more complex design.
panel provides fire protection, acoustic insulation and stability within
each unit without additional materials or treatment. The hotel element of the development consists of 130 bedrooms
including bars, restaurant and meeting rooms with the residential
FP McCann utilised a total of three erection teams comprising of eight
accommodation comprising one and two bedrooms apartments.
men per team, erecting an average of 45 units per day, finishing within
the strict time constraints set by the client. The hotel consists of 350
bedrooms, including disabled bedrooms.
fpmccann.co.uk/structural | 11EDUCATION
A precast concrete design solution provides affordable solutions for learning environments. Off-site
construction allows for educational buildings to be manufactured during term time with dramatically
reduced programme periods, allowing for erection to be completed during the school holidays, to ensure
little obstruction to school semesters.
M O NTGOME RY PRIM A RY SCH O O L , EXETER The precast concrete frame comprises of 104 external sandwich
panel walls and 84 internal walls, along with 217 floor and roof
Working closely with the architect NPS, FP McCann slab units. The sandwich panel thickness varies from 370 to
designed, manufactured and erected the precast 410mm and comes with between 50mm and 150mm of high-
performing rigid foam insulation already pre-installed and protected
structural components for the new school. behind thick concrete.
The sustainability of this project will be measured in the long-term
by the reduction of CO2 emissions. The inherent thermal mass
properties of concrete provide comfortable learning environments
without the use of air conditioning, and thus generates sizeable
energy cost savings for the end user. Since good acoustics are
also essential in schools and learning environments, the mass
and damping qualities of FP McCann’s precast concrete structure
address this important environmental aspect.
12 | fpmccann.co.uk/structuralJOHN PE RRY N PR IM A RY SCH O O L , L OND O N
M E DLO C K P R IM A RY & S UR E S TA RT
The design combines a 420-pupil Primary School with a 50-place C H ILDR E N’S C E NT R E , M A NC H E S T E R
nursery and Sure Start Children’s Centre.
In replacing the original Victorian school building, the design of
The two-storey education facility has 8 classrooms, staff room and Medlock School aimed to deliver a bold contemporary design for the
toilets on the first floor. On the ground floor there is an open-plan 21st century.
nursery provision, hall, dining room, IT suite, reception and a further 6
classrooms for 3-6 year olds, including toilets, administration and plant The three-storey educational facility has 12 classrooms and associated
room space. resource areas on the upper ww and first floors. On the lower ground
floor there is an open-plan nursery provision equating to seven nursery
A total of 479 units, 16 units per day were erected by FP McCann’s rooms, dining hall, kitchen, community use rooms, parent rooms,
own construction team, with a reduction of one week on the contract toilets, administration offices and plant room space. The design
programme. required an open-plan lower ground floor and standard classrooms on
the upper floors.
The upper floors are also designed with flexibility in mind. The corridor
walls to each room have been constructed in lightweight partition,
giving the school flexibility later, if required, to dismantle them and
utilise the space in a different way. A total of 460 units were erected by
FP McCann’s own construction team; erection completed in just five
weeks and one week earlier than the scheduled six-week timeframe.
R AVE NSBU RY CO M M UNITY PR IM A RY SC H O O L,
MAN C HE STE R
This project involved the amalgamation of the junior and infant schools
onto a single site to provide facilities sufficiently flexible to deliver
S T PA UL’S P R IM A RY S C H O O L, M A NC H ES T ER
education over the next 50 years. This project had a very short timescale, as the 192-pupil school
had to be completed in time for the new school year. Due to space
FP McCann played a key role in the design and construction of this constraints, the precast panels were delivered to site just-in-time. The
new two-storey primary school in East Manchester. overall structure was delivered and erected in just 19 days.
With a total floor area of 2,514 square metres, the building also The final structure provided a robust solution to this busy environment.
includes community facilities and a 60-place nursery. By using our Concrete panels were finished to the highest standard and paint could
precast concrete panel system, we were able to offer many benefits be applied directly to the finished concrete face.
to the scheme. The new structure was constructed in the adjoining
school grounds during term time. The use of limestone aggregates in the concrete mix enabled easy
post-fixing of the many accessories that was ultimately required in this
The quick erection programme and low noise of our modular educational environment.
construction provided the ideal solution to ensure the school was
ready for the start of the next academic year.
fpmccann.co.uk/structural | 13STUDENT
ACCOMMODATION
UNIV E R S IT Y O F T H E WE S T O F E NG LA ND, B R I S T O L
UNIV E R S IT Y O F WO R C E S T E R
The use of FP McCann’s crosswall system in student
accommodation gives significant benefits including robustness, fire
resistance, flood resistance, exceptional acoustics, thermal mass
and excellent security, all of which are essential for student living.
The student accommodation at the St. John’s campus comprises
of 192 bedrooms, 16 disabled bedrooms, 12 kitchens and 3 living
areas over its 3 storeys. FP McCann supplied the precast walls,
floors, stairs and landings. The external walls are 150mm thick
and the internal walls 180mm thick, requiring a total of 1,885m3 of
precast concrete.
14 | fpmccann.co.uk/structuralSTUDENT With the quality of campus life now a crucial factor
in determining students’ choice of educational
ACCOMMODATION establishments, many colleges and universities rely
on superior residential provision as a vital means of
attracting high-calibre scholars.
U N I VE RSI TY LO CKS, B IR M ING H A M thickness of 80mm. The insulation between the concrete faces is
either 250mm or 450mm thick.
The University Locks building has achieved a Breeam ‘Very Good’
rating. This project involved the construction of 659 student The outer 80mm skin of the Portland coloured concrete facade
rooms totalling 21,405m² in the form of cluster flats, with a main panels was cast with white cement and a selected decorative
southern tower standing at 19 storeys high. FP McCann’s precast aggregate, followed by a light acid etch to complete the surface
concrete modular room system was utilised, using a process finish.
where walls, floor and ceiling slabs are linked together to form a
unique crosswall construction. All horizontal and vertical sections were designed for ease of build,
and linked together with hidden tie rods. Joints were finished
In total, some 3,500 individual precast units were installed to form with a high-strength non-shrink grout, fully conforming to British
the structural frame and encompass the cladding envelope. The Standards. Walls were either battery cast or power-floated, which
five panels framing each pair of bedrooms consist of walls 180mm allowed for a simple gypsum wash prior to final decoration. The
thick and floor slabs 175mm thick. Window and door openings floors were given a pan float finish to the room side and steel
have been accommodated and each bedroom has four conduits mould finish to the ceiling. Individual bathroom pods were installed
cast into the walls for electrics and communications networks. as part of the build.
External facade panels are of sandwich panel construction, either
525mm or 725mm thick. The inner leaf is 195mm with an external
fpmccann.co.uk/structural | 15UNIVERSITY OF
One of our most innovative projects has been the development
of the University of East London’s campus at Royal Albert Docks.
EAST LONDON
The campus provides 788 student bed spaces and ancillary
facilities on a previously vacant site adjacent to the University’s
existing Docklands campus. Located opposite London City
Airport, the site is bounded by the Royal Albert Dock, a publicly
accessible dock edge path to the south, the Docklands Light
ST U DE N T AC C OM M O DATIO N Railway, Gallions Reach Roundabout, University Way to the
north and Woolwich Manor Way to the east. The building was
constructed using mainly precast concrete because of its inherent
16 | fpmccann.co.uk/structuralrobust nature, acoustic and thermal properties. This also helped The system provides a major contribution to the acoustic rating
eliminate wet trades, thus saving time and money and increasing for the external envelope; the choice of cladding dictates the final
the speed of erection. rating. This method of construction complies with the internal dB
ratings, as required by building regulations (Part E) for internal
One of the main advantages of FP McCann’s engineered precast party walls and floors, without surface treatment being necessary
concrete frame is that it provides a fair-faced finish to the walls. (except the floor coverings being applied). These unique attributes
This removes the need for plasterboard or a plaster skim. The help FP McCann’s precast structural building solutions reduce the
frame incorporates the internal walls (excluding the bedroom to overall cost and programme of the project. A fine example of all
corridor wall) and the inner skin of the external wall, thus omitting these benefits is the University of East London project.
the need for internal dry lined walls and external metal framed
walls.
fpmccann.co.uk/structural | 17SECURE
ACCOMMODATION
H M P D OVE GATE State-of-the-art AutoCad systems were used to build a 3D model
and co-ordinate the design development to ensure a successful
FP McCann was challenged to deliver this project project was delivered.
within a fast-track timescale. There were up to Benefits gained included a simplification of the various panel
11,000 individual elements which formed 12 types, improved quality and safety, together with more effective
different buildings, all of which had to be designed, sequencing during the manufacturing stage – thereby providing
valuable experience to carry forward on future projects.
manufactured and installed on-site by our teams.
FP McCann has also completed an extension to the existing
These formed over 800 cells and various recreational areas. prison, which consists of a 260 cell 2-storey, 4 winged ‘K’ shaped
Just-in- time deliveries enabled maximum productivity to be house block. The on-site erection was approximately 19 weeks,
achieved, with up to 10 erection gangs being utilised at the peak including the roof steel, during which time there were two crawler
of production. cranes and two mobile cranes in operation at any one time
erecting some 1,758 precast units and roof steels.
18 | fpmccann.co.uk/structuralOur range of precast modular building solutions
provide secure, sustainable, robust and cost-
effective solutions for Prisons and Young
Offenders Institutes. We have vast experience
within this sector and can ensure that a fully
coordinated design solution can be achieved to
meet any criteria.
FP McCann’s crosswall system of constructing multi-
unit accommodation has been used extensively in prison
construction over the last 15 years. The system has been
used in the construction of house blocks, segregation units
and associated prison buildings at over 25 different prison
sites.
fpmccann.co.uk/structural | 19HEALTH We support the public and private health sectors
with our experience and our range of precast
structures. FP McCann can provide concrete
solutions for hospitals and care homes, from design
and manufacture through to erection.
Engaging with clients from the earliest stage produces excellent
results. This way we can provide a scheme that will help to reduce
construction costs and delivery time by highlighting buildability
issues before they impact. It also enables us to add value through
innovative construction processes, producing standardisation and
value engineering.
H A FOD Y PARC CARE H O M E, A B ERGEL E
Abergele’s extra care housing scheme, Hafod y Parc is a 3-storey
development comprising of 49 affordable apartments, consisting
of 5 one bedroom apartments and 44 two bedroom apartments,
plus communal lounges, restaurant and a hobby room.
FP McCann was appointed by main contractor K & C Group
to design, manufacture and erect the walls, floors, stairs and
landings, including steel work.
The apartments are solely for residents who require extra care
facilities but want to maintain their independence.
20 | fpmccann.co.uk/structuralC O V E NT RY M E NTA L H E A LT H UNIT
This mental health unit has a footprint of 8,700 sq. metres and
was constructed alongside the existing hospital. It is mainly two
storey with a significant single storey element.
FP McCann worked closely with the main contractor to develop a
solution that offered the best combination of off-site manufacture
and speed of assembly on-site.
fpmccann.co.uk/structural | 21PRIVATE &
SOCIAL HOUSING
ST. J AME S C OU RT, BIRMINGHAM The top storey was a combination of a precast concrete crosswall
system and a lightweight steel frame. FP McCann was able to
St James’ Court is a luxury apartment development consisting
incorporate this combined steel and concrete solution into one
of four storeys constructed from a ground floor in-situ concrete
subcontract package.
transfer slab. The main contractor constructed the underground
car park and transfer slab using in-situ concrete. The limited working space within this site and its position adjacent
to a busy railway line dictated the use of a Factory Engineered
The first three floors were constructed using FP McCann’s modular
Concrete (FEC) modular system, and the use of just-in-time
flat-pack factory engineered concrete panels, providing internal
delivery of components was critical to this project.
structural load-bearing apartment dividing walls, together with
elevational panels. The structural envelope was completed with
the supply of precast stairs and landings.
22 | fpmccann.co.uk/structuralHigh value and low costs are paramount in the Options for dynamic and varied room layouts are available without
drastically compromising on costs and time.
residential development sector. Our precast concrete
structures provide the optimum sustainable solution FP McCann also has developed a method to construct individual
precast concrete housing, minimising project lengths and related
for apartments and private and social housing. costs that are associated with traditional build methods.
Crosswall construction has become an increasingly popular choice FP McCann will work with you to satisfy specific needs, whilst
for apartment construction because of the time and cost savings providing the most economical solutions possible.
that can be acheived.
T HE LAN SDOWNE B UIL DING , BIRMINGHA M Both the structural and architectural facade teams at FP McCann
worked closely with the designers SRC and Building Design Group
FP McCann’s precast concrete walls, columns, beams, stairs,
(BDG) architects on the project to ensure all aspects of the build
hollowcore flooring planks and architectural sandwich panels were
met the exacting specification standard. FP McCann took around
used on a brand new 16 storey, 206 unit residential apartment
nine days to complete each floor.
building called The Lansdowne.
fpmccann.co.uk/structural | 23CAR PARKS &
FRAMES
B EN E FI TS OF USING PRECA ST CONCRETE
FR A ME S
• Speed of construction is increased as follow-on trades can commence
much earlier
• Quick installation since structure is fabricated off-site
• Offsite construction enables high standard of workmanship in factory
A P P LICAT IO NS
conditions – reduces potential for accidents and is not affected by
weather or labour shortages, etc • Low-rise and multi-storey offices
• Wide variety of quality finishes achievable and concrete can be left • Elevated car parks
exposed
• Retail, industrial and warehousing developments
• Maintenance-free – no need to paint or periodically replace beams as
you would with alternative types of beams such as timber beams, which P R E CA S T C O NC R E T E CA R PA R K S
can rot, or steel beams – which can rust and corrode Precast multi-storey car park structures are designed and
manufactured using a number of structural precast elements,
• Fire resistant – concrete has its own built-in fire resistance, which can
including columns, beams, spandrels, stairs, liftshafts, hollowcore
also help to keep insurance costs down, etc. and there is no requirement
flooring slabs and wall panels. Due to their reduced self-weight,
for a site applied fire coating as with other systems
hollowcore flooring slabs can achieve clear spans of up to 16m;
• Economical – lower total cost: due to speed of construction, lower labour this reduces the requirements for vertical columns, creating better
costs as welders or skilled workers are not required for installation; manoeuvrability and therefore the risk of damage to vehicles and
concrete frames are not as expensive as steel beams and have lower the car park’s structure.
maintenance costs
K E Y FE AT UR E S
• High thermal capacity of concrete can reduce the demand for heating, • Quick off-loading and installation
ventilation and air conditioning, unlike alternative types of frames
• Designs and dimensions specified to suit project
• Flexible design – concrete can be cast into any shape, for example arch-
shaped beams, required to suit a variety of project plans and elevations • Standard dimensions available
GROUND BEAMS
FP McCann provides Ground Beams in lengths to span between
bases with a variety of end joint details. They can be designed to
support brick or block work or form a permanent shutter to the
edge of an in-situ concrete floor slab.
Fast spanning of
foundation bases.
24 | fpmccann.co.uk/structuralSUSTAINABLE Concrete in various forms has been used for
thousands of years. Today, precast concrete is
PERFORMANCE a widely used modern method of construction,
benefiting from the quality control a factory
environment can provide.
Precast concrete provides a quiet, comfortable, safe and durable
environment for occupants. The benefits of precast concrete can
BE NE FI TS OF PRECAST CO NCR ETE be best described under the following attributes:
D U RABI LI TY S P E E D O F C O NS T R UC T IO N
Precast concrete offers The nature of off-site
exceptional durability and long construction methods ensures
life in any structure. Concrete buildings can be erected
structures built over 100 quickly, even in adverse
years ago are still in active weather conditions, drastically
service today, which results in reducing construction time and
the timescale for replacing a associated costs.
precast concrete building being up to twice that of other forms of
construction; this durability, coupled with the energy efficiencies THERMAL MASS
that thermal mass brings, means that precast concrete has Thermal mass is concrete’s
low whole-life cycle costs when compared to other forms of ability to absorb and hold heat
construction. This longevity reduces disruption to the occupants and to release it in a controlled
and minimises breaks in any rental income stream for the building way, thus smoothing out the
owners. temperature variations within
the building over a 24-hour
FI RE RE SI STANCE
cycle and throughout the
Precast concrete is non- year. This thermal stability provides a more consistent internal
combustible. It does not add any environment, reduces the required heating loads and associated
fuel to a fire, help it to spread CO2 consumption over time. It also reduces the energy costs of
or produce any smoke or toxic buildings due to reduced energy consumption.
gases. It maintains its structural
integrity long after steel or timber A C O US T IC IS O LAT IO N P E R FO R M A NC E
structures have failed and can Precast concrete has excellent
be repaired following a fire. The risk of fire during and following acoustic performance. It has
construction is reduced, and if fire occurs, the effects are likely to the inherent mass, stiffness and
be less significant in terms of repair/replacement, greatly reducing damping properties necessary
the financial impact for the contractor/developer, building owner to effectively reduce the
and insurance companies. Occupiers can have greater confidence transmission of both airborne
that the building they are living or working in offers them better and impact sound. In fact,
protection against fire, and could be seen by the contractor/ concrete has the highest damping properties of any structural
developer as an aid to sales. material, reducing the reliance on additional finishes and simplifies
design and detailing. This leads to a reduction in the labour, time
FLOOD RE SI LIENCE
and costs associated with these finishes and detailing.
Precast concrete has excellent
flood resilience, maintaining R O B US T NE S S / S E C UR IT Y
its structural integrity during a The use of precast concrete
flood event. Its density resists creates a robust structure that
water penetration, reducing the reduces the risk of damage to
impact of a flood on the fabric of finishes and gives a sense of
the building, providing building security not necessarily felt in a
owners and insurance companies with reduced repair time and lightweight building. Couple this
costs associated with repairing flood damage. For occupiers, time with the reduced use of plaster
away from the property is reduced. board, we create a living space that can resist the wear and tear
of everyday life, keeping repair and maintenance costs down, year
Precast concrete is the ideal solution when building in areas
after year.
identified as being at risk from flooding.
fpmccann.co.uk/structural | 25PROJECT LIST Holiday Inn Express, Cowgate
Holiday Inn Express, Croydon
Holiday Inn Express, Derby
78
150
120
Holiday Inn Express, Winnersh
Holiday Inn Express, Witney
Hotel Brooklyn Portland Street,
174
N/A
Holiday Inn Express, Doncaster 94 Manchester 191
H OT E LS Holiday Inn Express, Dundee 93 Hotel Hampton by Hilton,
Holiday Inn Express, Epsom 120 Burton-on-Trent 86
No. of beds Holiday Inn Express, Exeter 122 Hotel La Tour, Birmingham 152
Arora Hotel, Crawley, Extension Block 96 Holiday Inn Express, Fulham 96 Howard Johnson Hotel, Glasgow 108
Arora Hotel, Crawley 311 Holiday Inn Express, Golders Green 83 Ibis, Aldgate 348
Casa Hotel, Chesterfield 100 Holiday Inn Express, Greenwich 162 Ibis, Birmingham 90
City Inn, Manchester 284 Holiday Inn Express, Hamilton 104 Ibis, Bradford 86
Crowne Plaza, London Docklands 210 Holiday Inn Express, Harlow 130 Ibis, Borehamwood 122
Crowne Plaza, Manchester 228 Holiday Inn Express, Ibis, Bristol Harbourside 180
Days Inn, Glasgow 110 Hemel Hempstead 112 Ibis, Carlisle 102
Etap/Ibis, Birmingham Airport 282 Holiday Inn Express, Kent 104 Ibis, Gatwick 131
Golden Tulip Hotel, Manchester 50 Holiday Inn Express, Kettering 121 Ibis, Hull 106
Hilton Burton-on-Trent 142 Holiday Inn Express, Leicester 109 Ibis, Leicester 150
Hilton Garden Inn, Stoke-on-Trent 138 Holiday Inn Express, Lincoln 118 Ibis, Liverpool 127
Hilton Hotel, Croydon 120 Holiday Inn Express, Luton Airport 147 Ibis, Luton Airport 64
Hilton Hotel, Edinburgh 110 Holiday Inn Express, Luton Airport, Ibis, Manchester 127
Hilton Hotel, Edinburgh 133 Extension Block 37 Ibis, Temple Quay 2, Bristol 141
Hilton Hotel, Heathrow T5 350 Holiday Inn Express, Manchester 150 Ibis, Wembley 210
Hilton Hotel, Luton 180 Holiday Inn Express, Manchester 193 Macdonalds Hotel, Sheffield 166
Holiday Inn, Commercial Rd, London 130 Holiday Inn Express, Milton Keynes 178 Malmaison Hotel, Liverpool 130
Holiday Inn, Glasgow 113 Holiday Inn Express, North Acton 108 Marriott Hotel, Cable Street
Holiday Inn, Newcastle 154 Holiday Inn Express, Northampton 127 Manchester 172
Holiday Inn, Norwich 150 Holiday Inn Express, Oldbury 109 Mercure Hotel, Swansea 102
Holiday Inn, Speke, Liverpool 100 Holiday Inn Express, Oxford 162 Motel One, Manchester & 328
Holiday Inn, Woking 161 Holiday Inn Express, Redbridge 126 Staycity Aparthotels, Manchester 256
Holiday Inn Express, Aberdeen N/A Holiday Inn Express, Redditch 100 Park Inn, Manchester 252
Holiday Inn Express, Ayr 108 Holiday Inn Express, Sheffield 161 Pentahotel, Derby 112
Holiday Inn Express, Barrow 127 Holiday Inn Express, Slough 142 Premier Inn, Dale Street, Manchester 193
Holiday Inn Express, Bath 126 Holiday Inn Express, Southampton 131 Premier Inn, Doncaster 107
Holiday Inn Express, Bath Holiday Inn Express, Southampton, Radisson Blu, Guildford 180
Extension Block 15 Extension Block 45 Radisson Blu, Jersey 166
Holiday Inn Express, Bedford 80 Holiday Inn Express, Stevenage 108 Ramada Encore, Birmingham NEC 120
Holiday Inn Express, Brentford Lock 120 Holiday Inn Express, Stoke 123 Ramada Encore, Chatham 93
Holiday Inn Express, Bridgewater 138 Holiday Inn Express, Stratford 114 Ramada Encore, Crewe 112
Holiday Inn Express, Bristol 133 Holiday Inn Express, Stratford, Ramada Encore, Doncaster 102
Holiday Inn Express, Bristol Extension Block 45 Ramada Encore, Haydock 102
Extension Block 24 Holiday Inn Express, Swiss Cottage 69 Ramada Encore, Newcastle 156
Holiday Inn Express, Burnley 98 Holiday Inn Express, Tamworth 120 Ramada Encore, Walsall 121
Holiday Inn Express, Cheltenham 100 Holiday Inn Express, Taunton 92 Splash Landings, Alton Towers 120
Holiday Inn Express, Holiday Inn Express, Walsall 100 The Armouries, Leeds 130
Chester Racecourse 97 Holiday Inn Express, Wandsworth 148 The Hoxton, Shoreditch, London 180
Holiday Inn Express, Chingford 102 Holiday Inn Express, Warwick 117 The International Hotel, Telford 101
Holiday Inn Express, Colchester 99 Holiday Inn Express, Watford 98
26 | fpmccann.co.uk/structuralTravelodge, Slough 180 University Locks, Birmingham 659 Phase 2C Block 3 42
Village Club Hotel, Ashton Moss 120 University of Essex, Colchester House 767 Phase 4 ‘The Cresent’ 55
Village Club Hotel, Elstree 120 University of Essex, Southend-on-Sea 561 Phase 4 ‘The Cube’ 50
Village Club Hotel, Farnborough 114 University of Hertfordshire 1601 St. James’s Court, Birmingham N/A
Village Club Hotel, Leeds South 115 University of Kent, Pier Rd, Gillingham 350 The Cargo Building,
Village Club Hotel, Solihull 122 University of Lincoln, Cygnet Court 500 Baltic Triangle, Liverpool 324
Westbridge Hotel, Stratford 75 University of London,
Docklands Campus 788
STUD E N T AC COMMODATION University of London, Malet Street 166 C US T O DIA L
University of London, London Mile End No. of cells
Road, Queen Mary Campus 595 HMP Jurby Prison – Isle of Man 200
No. of beds
University of London, Tufnell House 450 HMP Greenock Prison 64
Abertay University, Dundee 700
University of Southampton HMP Saughton Edinburgh 120
Birmingham City University, City Centre
Chamberlain Halls 350 HMP Glenochil Prison - Seg Unit 30
Campus (BCU)
University of Southampton HMP Polmont Prison - Seg Unit 30
Brunel University, London Phase 5 538
Portswood Road 500 HMP Perth Prison - Seg Unit 120
Buckingham New University,
University of Sussex 228 HMP Edinburgh 94
High Wycombe 200
University of the Arts, Camberwell 280 HMYOI Polmont 118
Buckingham New University,
University of the West of England, HMP Shotts Prison 285
High Wycombe 234
Bristol 1974 HMP Lowdham Grange 500
Cambridge University, North Cambridge
University of Worcester 177 HMP Kilmarnock Prison 500
Academy 321
University of Worcester 358 HMP Pucklechurch Remand Centre 400
Homerton College, Cambridge 138
Medomsley Secure Training Centre 40
Keele University, Staffordshire 500
Logford Detention Centre 400
Kings College, Great Dover St, London 350
HMP Hassockfield Prison 16
Lancaster University Phase 2 1870 M INIS T RY O F DE FE NC E HMP Lowdham Grange Expansion 30
Lancaster University Phase 3 1500
HMP Lowdham Grange Expansion 260
Loughborough University 661 No. of beds
Gatwick Immigration/Removal Centre 420
Loughborough University 700 JRSLA, Lucknow Barracks 450
Harmondsworth Immigration/Removal 196
Magna Carta, Runnymede (ongoing) 600 SNCO, Lucknow Barracks 50
HMP Coldingley 120
Manchester Metropolitan University, RAF Woodbridge 344
HMP Onley - House Block 120
Crewe Campus 51 RAF Woodbridge 58
HMP Bullingdon - House Block 110
Masons Hall, Birmingham 800 DACI Shrivenham 460
HMP Dovegate Prison 800
Newcastle University 300 DACI Shrivenham B36 250
HMP Liverpool 24
Pitfield St, Hackney 350
HMP Cardiff 20
Plymouth University 329 APA RT M E NT S HMP Albany - Hospital Wing N/A
Reading University, Bridges Hall 400 No. of apartments HMP Winchester 116
Reading University, Childs Hall 600 Browning Street, Birmingham N/A HMP Dovegate 264
Reading University, Didsbury Point, Manchester 45 HMP Littlehay Seg Unit 12
Stenton and Mackinder Halls 967 Fleet Street, Birmingham N/A HMP Parc 326
Reading University, Lansdowne House, Birmingham 206 HMP Belmarsh 600
Whiteknights Campus 120 Pocock Street, Birmingham N/A HMP Thameside (Belmarsh) 216
Selly Oak, Birmingham 480 Sadlers Park, Burslem Campus Phase 1 58 HMP Wrexham (Ancillary Buildings) N/A
Selly Oak, Birmingham (UNITE) 418 Sadlers Park, Burslem Campus Phase 2 64
Sheffield University N/A Sportcity, Manchester
Southbank University, London 300 Phase 2C Block 1 66
Swansea University 500 Phase 2C Block 2 57
fpmccann.co.uk/structural | 27BYLEY OFFICE: GRANTHAM OFFICE: LITTLEPORT OFFICE:
Byley Road Summit House Wisbech Road
Middlewich Alma Park Road Littleport
Cheshire Grantham, Lincolnshire Ely, Cambridgeshire
CW10 9RJ NG31 9SP CB6 1RA
T 01606 843500 T 01476 562277 T 01353 861416
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